Microporosity formed in the solidification process of Al alloys is detrimental to the alloy properties.A two-dimensional cellular automaton(CA)model was developed to simulate the microstructure and microporosity forma...Microporosity formed in the solidification process of Al alloys is detrimental to the alloy properties.A two-dimensional cellular automaton(CA)model was developed to simulate the microstructure and microporosity formation in Al-Cu alloys,considering variations in Cu content and solidification rate.The results indicate that the Cu content primarily influences the growth of microporosity.To validate the model,directional solidification experiments were conducted on Al-Cu alloys with varing Cu contents and withdrawal rates.The experimental results of dendrites and microporosity characteristics agree well with the predictions from the developed model,thus confirming the validity of the model.The alloy’s liquidus temperature,dendrite morphology,and hydrogen saturation solubility arising from different Cu contents have significant effects on microporosity morphology.The withdrawal rate primarily affects the nucleation of hydrogen microporosity by altering cooling rates and dendritic growth rates,resulting in different microporosity characteristics.展开更多
With the evolution of nickel-based single crystal superalloys,there is an increase in heavy elements such as Re and Ru.This has made solutal convection more pronounced during the directional solidification process,lea...With the evolution of nickel-based single crystal superalloys,there is an increase in heavy elements such as Re and Ru.This has made solutal convection more pronounced during the directional solidification process,leading to solute redistribution and increasing the risk of casting defects such as low-angle grain boundaries.To avoid casting defects,downward directional solidification(DWS)method is adopted to eliminate solutal convection and change solute redistribution.However,there is currently no in-situ characterization or quantitative simulation studying the solute redistribution during DWS and upward directional solidification(UWS)processes.A multicomponent phase field simulation coupled with lattice Boltzmann method was employed to quantitatively investigate changes in dendrite morphology,solutal convection and deviation of dendrite tips from the perspective of solute redistribution during UWS and DWS processes.The simulation of microstructure agrees well with the experimental results.The mechanism that explains how solutal convection affects side branching behavior is depicted.A novel approach is introduced to characterize dendrite deviation,elucidating the reasons why defects are prone to occur under the influence of natural convection and solute redistribution.展开更多
The obvious grain refinement of the primary MnSb phase has been observed in the Mn-89.7 wt%Sb alloy directionally solidified under a high-gradient magnetic field.With the application of a high-gradient magnetic field,...The obvious grain refinement of the primary MnSb phase has been observed in the Mn-89.7 wt%Sb alloy directionally solidified under a high-gradient magnetic field.With the application of a high-gradient magnetic field,the morphology of the primary MnSb phase transformed from developed dendritic-like to equiaxed-like,and the grain size decreased by approximately 93%.Refinement of the primary MnSb phase can be attributed to the constituent supercooling in front of the solidification interface,which promoted nucleation of the primary MnSb phase.The constituent supercooling can be linked to the enrichment of the Mn solute induced by the magnetic force and the Lorentz force that drove Mn solute migration and suppressed convection.展开更多
The magnetic field is an effective means to control the solidification structure and the defects of metal and semiconductor crystals.This work investigates the effects of Cusp magnetic field(CMF)and longitudinal magne...The magnetic field is an effective means to control the solidification structure and the defects of metal and semiconductor crystals.This work investigates the effects of Cusp magnetic field(CMF)and longitudinal magnetic field(LMF)on the stray-crystal formation in the platform regions during the directional solidification of single-crystal superalloy with the different cross section sizes.The application of CMF reduces the formation of platform stray-crystal,while LMF increases its generation.As the platform size increases,the stray-crystal ratio increases regardless of whether the magnetic fields are applied or not,the effectiveness of CMF increases,while that of LMF decreases.The reason that the effects of CMF and LMF on the platform stray-crystal formation could be attributed to the change of flow structure from the distribution characteristics of the thermoelectric magnetic force and the magnetic damping force near the liquid-solid interface.展开更多
Molecular dynamics(MD)simulations are employed to delve into the multifaceted effects of TiB_(2) nanoparticles on the intricate grain refinement mechanism,microstructural evolution,and tensile performance of Inconel 7...Molecular dynamics(MD)simulations are employed to delve into the multifaceted effects of TiB_(2) nanoparticles on the intricate grain refinement mechanism,microstructural evolution,and tensile performance of Inconel 718 superalloys during the rapid directional solidification.Specifically,the study focuses on elucidating the role of TiB2 nanoparticles in augmenting the nucleation rate during the rapid directional solidification process of Ni_(60)Cr_(21)Fe_(19) alloy system.Furthermore,subsequent tensile simulations are conducted to comprehensively evaluate the anisotropic behavior of tensile properties within the solidified microstructures.The MD results reveal that the incorporation of TiB₂nanoparticles during the rapid directional solidification of the Ni_(60)Cr_(21)Fe_(19) significantly enhances the average nucleation rate,escalating it from 1.27×10^(34)m^(-3)·s^(-1)to 2.55×10^(34)m^(-3)·s^(-1).Notably,within the face centered cube(FCC)structure,Ni atoms exhibit pronounced compositional segregation,and the solidified alloy maintains an exceptionally high dislocation density reaching up to 10^(16)m^(-2).Crucially,the rapid directional solidification process imparts a distinct microstructural anisotropy,leading to a notable disparity in tensile strength.Specifically,the tensile strength along the solidification direction is markedly superior to that perpendicular to it.This disparity arises from different deformation mechanisms under varying loading orientations.Tensile stress perpendicular to the solidification direction encourages the formation of smooth and organized mechanical twins.These twins act as slip planes,enhancing dislocation mobility and thereby improving stress relaxation and dispersion.Moreover,the results underscore the profound strengthening effect of TiB_(2) nanoparticles,particularly in enhancing the tensile strength along the rapid directional solidification direction.展开更多
In light of the difficult removal of harmful impurity tungsten(W)in Ce metal,in this paper a combined vacuum gravity sedimentation-directional solidification method was innovatively designed and the W separation behav...In light of the difficult removal of harmful impurity tungsten(W)in Ce metal,in this paper a combined vacuum gravity sedimentation-directional solidification method was innovatively designed and the W separation behavior was investigated.By reducing the electron beam power instantly and gradually at reduction rates of 1,3 and 5 kW/min,it is found that W is enriched at the bottom of ingots as the melt solidifies.The enrichment effect is much better than that of single purification method and the enrichment degree increases as the beam reduction rate decreases,attributed to the k0(W)>1 andρ(W)>ρ(Ce).Overall,the minimum content of W impurity can decrease from 630 to 0.1 ppm at the top of the ingot,and the purity of Ce increases from 99.932 wt%to 99.995 wt%by this combined method.Additionally,this paper provides a new method for the removal of high density and low evaporation coefficient impurities in low vapor pressure rare earth metals.展开更多
Study on turbine blades is crucial due to their critical role in ensuring the efficient and reliable operation of aircraft engines.Nickel-based single crystal superalloys are extensively used in the hot manufacturing ...Study on turbine blades is crucial due to their critical role in ensuring the efficient and reliable operation of aircraft engines.Nickel-based single crystal superalloys are extensively used in the hot manufacturing of turbine blades due to their exceptional high-temperature mechanical properties.The hot manufacturing of single crystal blades involves directional solidification and heat treatment.Experimental manufacturing of these blades is time-consuming,capital-intensive,and often insufficient to meet industrial demands.Numerical simulation techniques have gained widespread acceptance in blade manufacturing research due to their low energy consumption,high efficiency,and rapid turnaround time.This article introduces the modeling and simulation of hot manufacturing in single crystal blades.The discussion outlines the prevalent mathematical models employed in numerical simulations related to blade hot manufacturing.It encapsulates the advancements in research concerning macro to micro-level numerical simulation techniques for directional solidification and heat treatment processes.Furthermore,potential future trajectories for the numerical simulation of single crystal blade hot manufacturing are also discussed.展开更多
In this study,directional solidification was utilized to explore the relationship between microstructure,mechanical properties,and withdrawal speeds of Zn-55Al-1.6Si alloys.In order to assess the characteristics of Zn...In this study,directional solidification was utilized to explore the relationship between microstructure,mechanical properties,and withdrawal speeds of Zn-55Al-1.6Si alloys.In order to assess the characteristics of Zn-55Al-1.6Si alloys,both the microstructure and mechanical properties were thoroughly analyzed.This involved conducting room temperature tensile tests on samples with different withdrawal speeds(5,10,100,200,and 400μm·s^(-1)).The results reveal that both the as-cast alloy and samples after directional solidification are composed of zinc,aluminum,and silicon phases.As the withdrawal speed increases,an evident decrease in the size of the primary dendrites is observed.The results of tensile experiments show that Zn-55Al-1.6Si alloys after directional solidification exhibit brittle fracture characteristics,both the tensile strength and elongation of the alloys increase with withdrawal speed.展开更多
We proposed a new technique route of directional solidification for the manufacture of super slab.A 7-t laboratory-scale thick slab was casted and characterised for trial.To further understand the process,the evolutio...We proposed a new technique route of directional solidification for the manufacture of super slab.A 7-t laboratory-scale thick slab was casted and characterised for trial.To further understand the process,the evolution of the multiple physical fields during the directional solidification was simulated and verified.Similar to the convectional ingot casting,a negative segregated cone of equiaxed grains was formed at the bottom,and a seriously positive segregated region was formed beneath the top surface of the slab.Specific measures on the lateral walls,base plate,and free surface were strongly recommended to ensure that the slab is relatively directionally casted.A water-cooling copper base plate accelerates the solidification rate and the columnar growth along the vertical direction.It inhibits the sedimentation of equiaxed grains and enlarges the columnar zone.Based on the simulation analysis,it can be concluded that the directional solidification technique route is promising to manufacture super slab with lower segregation level,and less porosities and inclusions.展开更多
Surface recrystallization(RX) is a typical grain defect observed in directionally solidified(DS) Ni-based superalloys. Most studies have focused on the RX behavior and its impact on the mechanical properties of single...Surface recrystallization(RX) is a typical grain defect observed in directionally solidified(DS) Ni-based superalloys. Most studies have focused on the RX behavior and its impact on the mechanical properties of single-crystal(SC) superalloys, with limited research on its influence on the high-temperature mechanical properties of DS superalloys. This study systematically investigated the effect of RX on the high-temperature tensile properties of a DS DZ409 superalloy. The results show that at 650℃, the yield strength decreases almost linearly with an increase in RX fraction. A significant reduction in elongation is observed as the RX fraction increases from 0% to 4.9%. However, beyond this point, further increase in RX fraction leads to minimal changes in elongation. At 950℃, both yield strength and elongation decrease as the RX fraction increases from 0% to 4.9%. At 650℃, fractures in the RX DS superalloys exhibit a mixed mode of transgranular and intergranular cleavage fracture, while at 950℃, it features a combination of ductile and intergranular dimple fractures. The failure mechanism of the RX DS superalloy is associated with the introduction of transverse grain boundaries(GBs) during RX. In the early stages of tensile testing at intermediate and high temperatures, cracks can easily initiate at these GBs. Subsequently, the cracks propagate along the GBs into the DS matrix, ultimately leading to failure of the DS superalloy.展开更多
To improve the power efficiency and optimize the configuration of cold crucible using for continuous melting and directional solidification （DS）, based on experimental verification, 3D finite element （FE） models w...To improve the power efficiency and optimize the configuration of cold crucible using for continuous melting and directional solidification （DS）, based on experimental verification, 3D finite element （FE） models with various configuration-elements were developed to investigate the magnetic field in cold crucible. Magnetic flux density （B） was measured and calculated under different configuration parameters. These parameters include the inner diameter （D2）, the slit width （d）, the thickness of crucible wall, the section shape of the slit and the shield ring. The results show that the magnetic flux density in z direction （Bz） both at the slit and at the midpoint of segment will increase with the decrease of D2 or with the increase of the width of the slit and the section area of wedge slit or removing the shield ring. In addition, there is a worst wall thickness that can induce the minimum Bz for a cold crucible with a certain outer diameter.展开更多
A vacuum directional solidification with high temperature gradient was performed to prepare low cost solar-grade multicrystalline silicon （mc-Si） directly from metallurgical-grade mc-Si. The microstructure character...A vacuum directional solidification with high temperature gradient was performed to prepare low cost solar-grade multicrystalline silicon （mc-Si） directly from metallurgical-grade mc-Si. The microstructure characteristic, grain size, boundary, solid-liquid growth interface, and dislocation structure under different growth conditions were studied. The results show that directionally solidified multicrystalline silicon rods with high density and orientation can be obtained when the solidification rate is below 60 μm/s. The grain size gradually decreases with increasing the solidification rate. The control of obtaining planar solid-liquid interface at high temperature gradient is effective to produce well-aligned columnar grains along the solidification direction. The growth step and twin boundaries are preferred to form in the microstructure due to the faceted growth characteristic of mc-Si. The dislocation distribution is inhomogeneous within crystals and the dislocation density increases with the increase of solidification rate. Furthermore, the crystal growth behavior and dislocation formation mechanism of mc-Si were discussed.展开更多
The influence of melt convection on dendrite growth during the upward-directional solidification of Pb-33%Sn binary alloys was investigated.The melt convection was modulated by traveling magnetic field.When the direct...The influence of melt convection on dendrite growth during the upward-directional solidification of Pb-33%Sn binary alloys was investigated.The melt convection was modulated by traveling magnetic field.When the direction of traveling magnetic field was changed from upward to downward,the primary dendrite spacing gradually increased,and the distribution peak of the primary dendrite spacing shifted to the field of narrower spacing.These result from the different intensities of melt convection,which are controlled by the traveling magnetic field.The effects of the traveling magnetic field on melt convection are similar to those of adjustment in the gravity level,thus,the primary dendrite spacing varies.When the intensity of the traveling magnetic field was 1 mT,and the drawing speed was 50 μm/s,the gravity acceleration reached 0.22g for the downward-traveling magnetic field and 3.07g for the upward-traveling magnetic field.展开更多
Ni-45.5Al-9Mo （mole fraction,%） alloy was directionally solidified with a constant temperature gradient （GL=334 K/cm） and growth rates ranging from 2 to 300 μm/s using a Bridgman type crystal growing facility wit...Ni-45.5Al-9Mo （mole fraction,%） alloy was directionally solidified with a constant temperature gradient （GL=334 K/cm） and growth rates ranging from 2 to 300 μm/s using a Bridgman type crystal growing facility with liquid metal cooling （LMC） technique. The effect of growth rate （v） on the solidified microstructures such as rod spacing （λ）, rod size （d） and rod volume fraction was experimentally investigated. Two types of the solidified interfaces, planar and cellular, were identified. On the condition of both planar and cellular eutectic microstructures, the relationships between λ, d and v were given as： λv1/2=5.90 μm·μm1/2·s1/2 and dv1/2=2.18μm·μm1/2·s1/2, respectively. It was observed that the volume fraction of Mo phase could be adjusted in a certain range. The variation of phase volume fraction was attributed to undercooling increase and the growth characteristics of the individual constituent phases during the eutectic growth.展开更多
Directional solidification experiments on Pb-Bi peritectic alloys were carried out at very low growth rate （v=0.5 μm/s） and high temperature gradient （G=35 K/mm） in an improved Bridgman furnace. The banding struc...Directional solidification experiments on Pb-Bi peritectic alloys were carried out at very low growth rate （v=0.5 μm/s） and high temperature gradient （G=35 K/mm） in an improved Bridgman furnace. The banding structures were observed in both hypoperitectic and hyperperitectic compositions （Pb-xBi, x=26%, 28%, 30% and 34%）. Tree-like primary α phase in the center of the sample surrounded by the peritectic β phase matrix was also observed, resulting from the melt convection. The banding microstructure, however, is found to be transient after the tree-like structure and only the peritectic phase forms after a few bands. Composition variations in the banding structure are measured to determine the nucleation undercooling for both α and β phases. In a finite length sample, convection is shown to lead only to the transient formation of bands. In this transient banding regime, only a few bands with a variable width are formed, and this transient banding process can occur over a wide range of compositions inside the two-phase peritectic region.展开更多
Redistribution of iron during directional solidification of metallurgical-grade silicon (MG-Si) was conducted at low growth rate. Concentrations of iron were examined by ICP-MS and figured in solid and liquid phases, ...Redistribution of iron during directional solidification of metallurgical-grade silicon (MG-Si) was conducted at low growth rate. Concentrations of iron were examined by ICP-MS and figured in solid and liquid phases, at grain boundary and in growth direction. Concentrations are significantly different between solid and liquid phases. The thickness of the solute boundary layer is about 4 mm verified by mass balance law, and the effective distribution coefficient is 2.98×10?4. Iron element easily segregates at grain boundary at low growth rate. In growth direction, concentrations are almost constant until 86% ingot height, and they do not meet the Scheil equation completely, which is caused by the low growth rate. The effect of convection on the redistribution of iron was discussed in detail. Especially, the “dead zone” of convection plays an important role in the iron redistribution.展开更多
A γ-TiAl alloy with nominal composition of Ti-47%Al（molar fraction） was directionally solidified in an alumina mould with an Y2O3 protective coating.The effects of processing parameters（melting temperature and int...A γ-TiAl alloy with nominal composition of Ti-47%Al（molar fraction） was directionally solidified in an alumina mould with an Y2O3 protective coating.The effects of processing parameters（melting temperature and interaction time） on the metal-coating interface,microstructure and chemical composition of the alloy were evaluated.The result shows that the Y2O3 protective coating exhibits an effective barrier capability to avoid direct contact between the mould base material and the TiAl melt,although the Y2O3 coating is found to suffer some erosion and be slightly dissolved by the molten TiAl due to the coating-metal interactions.The directionally solidified alloys were contaminated with Y and O,and Y2O3 inclusions were dispersed in the metal matrix.The reason for this metal contamination is the Y2O3 coating dissolution by the TiAl melt.One mode of the interaction between Y2O3 and the TiAl melt is dissolution of yttrium and atomic oxygen in the melt by reaction Y2O3（s）=2Y（in TiAl melt）＋3O（in TiAl melt）.Both the extent of alloy contamination and the volume fractions of Y2O3 inclusions depend on the melting temperature and the interaction time.展开更多
An overview of the development and current status of the directional solidification process assisted by liquid metal cooling （LMC） has been presented in this paper. The driving force of the rapid development of the ...An overview of the development and current status of the directional solidification process assisted by liquid metal cooling （LMC） has been presented in this paper. The driving force of the rapid development of the LMC process has been analyzed by considering the demands of （1） newer technologies that can provide higher thermal gradients for alleviated segregation in advanced alloy systems, and （2） better production yield of the large directionally solidified superalloy components. The brief history of the industrialization of the LMC process has been reviewed, followed by the discussion on the LMC parameters including selection of the cooling media, using of the dynamic baffle, and the influence of withdrawal rates and so on. The microstructure and mechanical properties of the traditional superalloys processed by LMC, as well as the new alloys particularly developed for LMC process were then described. Finally, future aspects concerning the LMC process have been summarized.展开更多
The low voltage pulsed magnetic field(LVPMF)disrupts the columnar dendrite growth,and the columnarto-equiaxed transition(CET)occurs during the directional solidification of superalloy K4169.Within the pulse voltage ra...The low voltage pulsed magnetic field(LVPMF)disrupts the columnar dendrite growth,and the columnarto-equiaxed transition(CET)occurs during the directional solidification of superalloy K4169.Within the pulse voltage ranging from 100Vto 200 V,a transition from columnar to equiaxed grain was observed,and the grain size decreased as the pulse voltage rised.As the pulse frequency increased,the CET occurred,and the grains were refined.However,the grains became coarse,and the solidification structure was columnar crystal again when frequency increased to 10 Hz.The LVPMF had an optimal frequency to promote CET.The LVPMF on the CET was affected by the withdrawal speed and increasing the withdrawal speed enhances the CET.The distribution of electromagnetic force and flow field in the melt under the LVPMF were modeled and simulated to reveal the CET mechanism.It is considered that the CET should be attributed to the coupling effects of magnetic vibration and melt convection induced by the LVPMF.展开更多
The process of grain selection in the spiral selector was investigated by both a ProCAST simulation based on a cellular automaton finite element（CAFE） model and experimental confirmation.The results show that the he...The process of grain selection in the spiral selector was investigated by both a ProCAST simulation based on a cellular automaton finite element（CAFE） model and experimental confirmation.The results show that the height of starter block,the spiral diameter and initial angle play an important role in grain selection.The dimension of selector should be maintained in a stable range to optimize the grain orientation and select a single crystal efficiently.A selector which can efficiently select a single crystal had been successfully designed.Grain orientation fluctuation in the spiral part was also studied by means of the variation of thermal condition.展开更多
基金financially supported by the National Natural Science Foundation of China(Grant No.51875211)the Beijing Natural Science Foundation(Grant No.L223001)。
文摘Microporosity formed in the solidification process of Al alloys is detrimental to the alloy properties.A two-dimensional cellular automaton(CA)model was developed to simulate the microstructure and microporosity formation in Al-Cu alloys,considering variations in Cu content and solidification rate.The results indicate that the Cu content primarily influences the growth of microporosity.To validate the model,directional solidification experiments were conducted on Al-Cu alloys with varing Cu contents and withdrawal rates.The experimental results of dendrites and microporosity characteristics agree well with the predictions from the developed model,thus confirming the validity of the model.The alloy’s liquidus temperature,dendrite morphology,and hydrogen saturation solubility arising from different Cu contents have significant effects on microporosity morphology.The withdrawal rate primarily affects the nucleation of hydrogen microporosity by altering cooling rates and dendritic growth rates,resulting in different microporosity characteristics.
基金supported by the stable support project and the Major National Science and Technology Project(2017-VII-0008-0101).
文摘With the evolution of nickel-based single crystal superalloys,there is an increase in heavy elements such as Re and Ru.This has made solutal convection more pronounced during the directional solidification process,leading to solute redistribution and increasing the risk of casting defects such as low-angle grain boundaries.To avoid casting defects,downward directional solidification(DWS)method is adopted to eliminate solutal convection and change solute redistribution.However,there is currently no in-situ characterization or quantitative simulation studying the solute redistribution during DWS and upward directional solidification(UWS)processes.A multicomponent phase field simulation coupled with lattice Boltzmann method was employed to quantitatively investigate changes in dendrite morphology,solutal convection and deviation of dendrite tips from the perspective of solute redistribution during UWS and DWS processes.The simulation of microstructure agrees well with the experimental results.The mechanism that explains how solutal convection affects side branching behavior is depicted.A novel approach is introduced to characterize dendrite deviation,elucidating the reasons why defects are prone to occur under the influence of natural convection and solute redistribution.
基金supported by the National Key R&D Program of China(Grant No.2021YFB3501404)the fund of the State Key Laboratory of Solidification Processing in NWPU(Grant No.SKLSP202101).
文摘The obvious grain refinement of the primary MnSb phase has been observed in the Mn-89.7 wt%Sb alloy directionally solidified under a high-gradient magnetic field.With the application of a high-gradient magnetic field,the morphology of the primary MnSb phase transformed from developed dendritic-like to equiaxed-like,and the grain size decreased by approximately 93%.Refinement of the primary MnSb phase can be attributed to the constituent supercooling in front of the solidification interface,which promoted nucleation of the primary MnSb phase.The constituent supercooling can be linked to the enrichment of the Mn solute induced by the magnetic force and the Lorentz force that drove Mn solute migration and suppressed convection.
基金supported by the National Natural Science Foundation of China(No.52373319)by the Independent Research and Development Project of State Key Laboratory of Advanced Special Steel,Shanghai Key Laboratory of Advanced Ferrometallurgy,Shanghai University(SKLASS 2022-Z03).
文摘The magnetic field is an effective means to control the solidification structure and the defects of metal and semiconductor crystals.This work investigates the effects of Cusp magnetic field(CMF)and longitudinal magnetic field(LMF)on the stray-crystal formation in the platform regions during the directional solidification of single-crystal superalloy with the different cross section sizes.The application of CMF reduces the formation of platform stray-crystal,while LMF increases its generation.As the platform size increases,the stray-crystal ratio increases regardless of whether the magnetic fields are applied or not,the effectiveness of CMF increases,while that of LMF decreases.The reason that the effects of CMF and LMF on the platform stray-crystal formation could be attributed to the change of flow structure from the distribution characteristics of the thermoelectric magnetic force and the magnetic damping force near the liquid-solid interface.
基金supported by the Na⁃tional Natural Science Foundation of China(Nos.12462006,12062016)the high-performance computing services of⁃fered by the Information Center of Nanchang Hangkong Uni⁃versity.
文摘Molecular dynamics(MD)simulations are employed to delve into the multifaceted effects of TiB_(2) nanoparticles on the intricate grain refinement mechanism,microstructural evolution,and tensile performance of Inconel 718 superalloys during the rapid directional solidification.Specifically,the study focuses on elucidating the role of TiB2 nanoparticles in augmenting the nucleation rate during the rapid directional solidification process of Ni_(60)Cr_(21)Fe_(19) alloy system.Furthermore,subsequent tensile simulations are conducted to comprehensively evaluate the anisotropic behavior of tensile properties within the solidified microstructures.The MD results reveal that the incorporation of TiB₂nanoparticles during the rapid directional solidification of the Ni_(60)Cr_(21)Fe_(19) significantly enhances the average nucleation rate,escalating it from 1.27×10^(34)m^(-3)·s^(-1)to 2.55×10^(34)m^(-3)·s^(-1).Notably,within the face centered cube(FCC)structure,Ni atoms exhibit pronounced compositional segregation,and the solidified alloy maintains an exceptionally high dislocation density reaching up to 10^(16)m^(-2).Crucially,the rapid directional solidification process imparts a distinct microstructural anisotropy,leading to a notable disparity in tensile strength.Specifically,the tensile strength along the solidification direction is markedly superior to that perpendicular to it.This disparity arises from different deformation mechanisms under varying loading orientations.Tensile stress perpendicular to the solidification direction encourages the formation of smooth and organized mechanical twins.These twins act as slip planes,enhancing dislocation mobility and thereby improving stress relaxation and dispersion.Moreover,the results underscore the profound strengthening effect of TiB_(2) nanoparticles,particularly in enhancing the tensile strength along the rapid directional solidification direction.
基金Project supported by the National Key Research and Development Program of China(2022YFC2905203)the NationalScience and Technology Major Project of China(J2019-VI-0023-0140)。
文摘In light of the difficult removal of harmful impurity tungsten(W)in Ce metal,in this paper a combined vacuum gravity sedimentation-directional solidification method was innovatively designed and the W separation behavior was investigated.By reducing the electron beam power instantly and gradually at reduction rates of 1,3 and 5 kW/min,it is found that W is enriched at the bottom of ingots as the melt solidifies.The enrichment effect is much better than that of single purification method and the enrichment degree increases as the beam reduction rate decreases,attributed to the k0(W)>1 andρ(W)>ρ(Ce).Overall,the minimum content of W impurity can decrease from 630 to 0.1 ppm at the top of the ingot,and the purity of Ce increases from 99.932 wt%to 99.995 wt%by this combined method.Additionally,this paper provides a new method for the removal of high density and low evaporation coefficient impurities in low vapor pressure rare earth metals.
基金supported by the Stable Support Project and the Major National Science and Technology Project(Grant No.2017-VII-0008-0101).
文摘Study on turbine blades is crucial due to their critical role in ensuring the efficient and reliable operation of aircraft engines.Nickel-based single crystal superalloys are extensively used in the hot manufacturing of turbine blades due to their exceptional high-temperature mechanical properties.The hot manufacturing of single crystal blades involves directional solidification and heat treatment.Experimental manufacturing of these blades is time-consuming,capital-intensive,and often insufficient to meet industrial demands.Numerical simulation techniques have gained widespread acceptance in blade manufacturing research due to their low energy consumption,high efficiency,and rapid turnaround time.This article introduces the modeling and simulation of hot manufacturing in single crystal blades.The discussion outlines the prevalent mathematical models employed in numerical simulations related to blade hot manufacturing.It encapsulates the advancements in research concerning macro to micro-level numerical simulation techniques for directional solidification and heat treatment processes.Furthermore,potential future trajectories for the numerical simulation of single crystal blade hot manufacturing are also discussed.
基金funded by the Key Science and Technology Projects of Gansu Province(Grant No.22ZD6GB019)the Gansu Key Research and Development Project(Grant No.23YFGA0003)+2 种基金the Gansu Provincial Joint Research Fund(Grant No.23JRRC0004)the Fundamental Research Funds for the Central Universities(Grant No.lzujbky-2022-ey15)the fund of the State Key Laboratory of Solidification Processing in NPU(Grant No.SKLSP202204).
文摘In this study,directional solidification was utilized to explore the relationship between microstructure,mechanical properties,and withdrawal speeds of Zn-55Al-1.6Si alloys.In order to assess the characteristics of Zn-55Al-1.6Si alloys,both the microstructure and mechanical properties were thoroughly analyzed.This involved conducting room temperature tensile tests on samples with different withdrawal speeds(5,10,100,200,and 400μm·s^(-1)).The results reveal that both the as-cast alloy and samples after directional solidification are composed of zinc,aluminum,and silicon phases.As the withdrawal speed increases,an evident decrease in the size of the primary dendrites is observed.The results of tensile experiments show that Zn-55Al-1.6Si alloys after directional solidification exhibit brittle fracture characteristics,both the tensile strength and elongation of the alloys increase with withdrawal speed.
基金the National Natural Science Foundation of China(No.52074182)Joint Funds of the National Natural Science Foundation of China(No.U23A20612).
文摘We proposed a new technique route of directional solidification for the manufacture of super slab.A 7-t laboratory-scale thick slab was casted and characterised for trial.To further understand the process,the evolution of the multiple physical fields during the directional solidification was simulated and verified.Similar to the convectional ingot casting,a negative segregated cone of equiaxed grains was formed at the bottom,and a seriously positive segregated region was formed beneath the top surface of the slab.Specific measures on the lateral walls,base plate,and free surface were strongly recommended to ensure that the slab is relatively directionally casted.A water-cooling copper base plate accelerates the solidification rate and the columnar growth along the vertical direction.It inhibits the sedimentation of equiaxed grains and enlarges the columnar zone.Based on the simulation analysis,it can be concluded that the directional solidification technique route is promising to manufacture super slab with lower segregation level,and less porosities and inclusions.
基金supported by the National Science and Technology Major Project(No.HT-J2019-VI-0020-0136)the National Youth Talent Support Program,and the Fundamental Research Funds for the Central Universities(No.xtr072024004).
文摘Surface recrystallization(RX) is a typical grain defect observed in directionally solidified(DS) Ni-based superalloys. Most studies have focused on the RX behavior and its impact on the mechanical properties of single-crystal(SC) superalloys, with limited research on its influence on the high-temperature mechanical properties of DS superalloys. This study systematically investigated the effect of RX on the high-temperature tensile properties of a DS DZ409 superalloy. The results show that at 650℃, the yield strength decreases almost linearly with an increase in RX fraction. A significant reduction in elongation is observed as the RX fraction increases from 0% to 4.9%. However, beyond this point, further increase in RX fraction leads to minimal changes in elongation. At 950℃, both yield strength and elongation decrease as the RX fraction increases from 0% to 4.9%. At 650℃, fractures in the RX DS superalloys exhibit a mixed mode of transgranular and intergranular cleavage fracture, while at 950℃, it features a combination of ductile and intergranular dimple fractures. The failure mechanism of the RX DS superalloy is associated with the introduction of transverse grain boundaries(GBs) during RX. In the early stages of tensile testing at intermediate and high temperatures, cracks can easily initiate at these GBs. Subsequently, the cracks propagate along the GBs into the DS matrix, ultimately leading to failure of the DS superalloy.
基金Project (2011CB605504) supported by the National Basic Research Program of China
文摘To improve the power efficiency and optimize the configuration of cold crucible using for continuous melting and directional solidification （DS）, based on experimental verification, 3D finite element （FE） models with various configuration-elements were developed to investigate the magnetic field in cold crucible. Magnetic flux density （B） was measured and calculated under different configuration parameters. These parameters include the inner diameter （D2）, the slit width （d）, the thickness of crucible wall, the section shape of the slit and the shield ring. The results show that the magnetic flux density in z direction （Bz） both at the slit and at the midpoint of segment will increase with the decrease of D2 or with the increase of the width of the slit and the section area of wedge slit or removing the shield ring. In addition, there is a worst wall thickness that can induce the minimum Bz for a cold crucible with a certain outer diameter.
基金Projects (51002122, 51272211) supported by the National Natural Science Foundation of ChinaProject (2010ZF53064) supported by the Aeronautical Science Foundation of China+3 种基金Project (2012M51028) supported by the Postdoctoral Science Foundation of ChinaProject (2010JQ6005) supported by the Natural Science Foundation of Shaanxi Province, ChinaProject (76-QP-2011) supported by the Research Fund of State Key Laboratory of Solidification Processing in NWPU, ChinaProject (B08040) supported by the 111Project, China
文摘A vacuum directional solidification with high temperature gradient was performed to prepare low cost solar-grade multicrystalline silicon （mc-Si） directly from metallurgical-grade mc-Si. The microstructure characteristic, grain size, boundary, solid-liquid growth interface, and dislocation structure under different growth conditions were studied. The results show that directionally solidified multicrystalline silicon rods with high density and orientation can be obtained when the solidification rate is below 60 μm/s. The grain size gradually decreases with increasing the solidification rate. The control of obtaining planar solid-liquid interface at high temperature gradient is effective to produce well-aligned columnar grains along the solidification direction. The growth step and twin boundaries are preferred to form in the microstructure due to the faceted growth characteristic of mc-Si. The dislocation distribution is inhomogeneous within crystals and the dislocation density increases with the increase of solidification rate. Furthermore, the crystal growth behavior and dislocation formation mechanism of mc-Si were discussed.
基金Project(50827102)supported by the National Natural Science Foundation of ChinaProject(2010CB631202)supported by the National Basic Research Program of ChinaProject(28-TP-2009)supported by Research Fund of State Key Laboratory of Solidification Processing(NWPU),China
文摘The influence of melt convection on dendrite growth during the upward-directional solidification of Pb-33%Sn binary alloys was investigated.The melt convection was modulated by traveling magnetic field.When the direction of traveling magnetic field was changed from upward to downward,the primary dendrite spacing gradually increased,and the distribution peak of the primary dendrite spacing shifted to the field of narrower spacing.These result from the different intensities of melt convection,which are controlled by the traveling magnetic field.The effects of the traveling magnetic field on melt convection are similar to those of adjustment in the gravity level,thus,the primary dendrite spacing varies.When the intensity of the traveling magnetic field was 1 mT,and the drawing speed was 50 μm/s,the gravity acceleration reached 0.22g for the downward-traveling magnetic field and 3.07g for the upward-traveling magnetic field.
基金Project (51074128) supported by the National Natural Science Foundation of ChinaProject (2007ZF53067) supported by the Aeronautical Science Foundation of China+1 种基金Project (2010JM6002) supported by the Natural Science Foundation of Shaanxi Province of ChinaProjec t(2012NCL004) supported by the Innovation Foundation of Inner Mongolia University of Science and Technology
文摘Ni-45.5Al-9Mo （mole fraction,%） alloy was directionally solidified with a constant temperature gradient （GL=334 K/cm） and growth rates ranging from 2 to 300 μm/s using a Bridgman type crystal growing facility with liquid metal cooling （LMC） technique. The effect of growth rate （v） on the solidified microstructures such as rod spacing （λ）, rod size （d） and rod volume fraction was experimentally investigated. Two types of the solidified interfaces, planar and cellular, were identified. On the condition of both planar and cellular eutectic microstructures, the relationships between λ, d and v were given as： λv1/2=5.90 μm·μm1/2·s1/2 and dv1/2=2.18μm·μm1/2·s1/2, respectively. It was observed that the volume fraction of Mo phase could be adjusted in a certain range. The variation of phase volume fraction was attributed to undercooling increase and the growth characteristics of the individual constituent phases during the eutectic growth.
基金Project (20110491492) supported by the China Postdoctoral Science FoundationProject (20114BAB216017) supported by the Natural Science Foundation of Jiangxi Province, ChinaProject (GJJ12035) supported by the Science Foundation of the Educational Department of Jiangxi Province, China
文摘Directional solidification experiments on Pb-Bi peritectic alloys were carried out at very low growth rate （v=0.5 μm/s） and high temperature gradient （G=35 K/mm） in an improved Bridgman furnace. The banding structures were observed in both hypoperitectic and hyperperitectic compositions （Pb-xBi, x=26%, 28%, 30% and 34%）. Tree-like primary α phase in the center of the sample surrounded by the peritectic β phase matrix was also observed, resulting from the melt convection. The banding microstructure, however, is found to be transient after the tree-like structure and only the peritectic phase forms after a few bands. Composition variations in the banding structure are measured to determine the nucleation undercooling for both α and β phases. In a finite length sample, convection is shown to lead only to the transient formation of bands. In this transient banding regime, only a few bands with a variable width are formed, and this transient banding process can occur over a wide range of compositions inside the two-phase peritectic region.
基金Projects(51334004,51204143)supported by the National Natural Science Foundation of ChinaProject(2006L2003)supported by the Scientific Technological Innovation Platform of Fujian Province,China
文摘Redistribution of iron during directional solidification of metallurgical-grade silicon (MG-Si) was conducted at low growth rate. Concentrations of iron were examined by ICP-MS and figured in solid and liquid phases, at grain boundary and in growth direction. Concentrations are significantly different between solid and liquid phases. The thickness of the solute boundary layer is about 4 mm verified by mass balance law, and the effective distribution coefficient is 2.98×10?4. Iron element easily segregates at grain boundary at low growth rate. In growth direction, concentrations are almost constant until 86% ingot height, and they do not meet the Scheil equation completely, which is caused by the low growth rate. The effect of convection on the redistribution of iron was discussed in detail. Especially, the “dead zone” of convection plays an important role in the iron redistribution.
文摘A γ-TiAl alloy with nominal composition of Ti-47%Al（molar fraction） was directionally solidified in an alumina mould with an Y2O3 protective coating.The effects of processing parameters（melting temperature and interaction time） on the metal-coating interface,microstructure and chemical composition of the alloy were evaluated.The result shows that the Y2O3 protective coating exhibits an effective barrier capability to avoid direct contact between the mould base material and the TiAl melt,although the Y2O3 coating is found to suffer some erosion and be slightly dissolved by the molten TiAl due to the coating-metal interactions.The directionally solidified alloys were contaminated with Y and O,and Y2O3 inclusions were dispersed in the metal matrix.The reason for this metal contamination is the Y2O3 coating dissolution by the TiAl melt.One mode of the interaction between Y2O3 and the TiAl melt is dissolution of yttrium and atomic oxygen in the melt by reaction Y2O3（s）=2Y（in TiAl melt）＋3O（in TiAl melt）.Both the extent of alloy contamination and the volume fractions of Y2O3 inclusions depend on the melting temperature and the interaction time.
文摘An overview of the development and current status of the directional solidification process assisted by liquid metal cooling （LMC） has been presented in this paper. The driving force of the rapid development of the LMC process has been analyzed by considering the demands of （1） newer technologies that can provide higher thermal gradients for alleviated segregation in advanced alloy systems, and （2） better production yield of the large directionally solidified superalloy components. The brief history of the industrialization of the LMC process has been reviewed, followed by the discussion on the LMC parameters including selection of the cooling media, using of the dynamic baffle, and the influence of withdrawal rates and so on. The microstructure and mechanical properties of the traditional superalloys processed by LMC, as well as the new alloys particularly developed for LMC process were then described. Finally, future aspects concerning the LMC process have been summarized.
基金supported by the National Natural Science Foundation of China(No.51674236)the Key Research and Development Program of Liaoning Province(2019JH2/10100009)+1 种基金the National Science and Technology Major Project(No.2017-VI-00-0073)the National Key Research and Development Program(No.2018YFA0702900).
文摘The low voltage pulsed magnetic field(LVPMF)disrupts the columnar dendrite growth,and the columnarto-equiaxed transition(CET)occurs during the directional solidification of superalloy K4169.Within the pulse voltage ranging from 100Vto 200 V,a transition from columnar to equiaxed grain was observed,and the grain size decreased as the pulse voltage rised.As the pulse frequency increased,the CET occurred,and the grains were refined.However,the grains became coarse,and the solidification structure was columnar crystal again when frequency increased to 10 Hz.The LVPMF had an optimal frequency to promote CET.The LVPMF on the CET was affected by the withdrawal speed and increasing the withdrawal speed enhances the CET.The distribution of electromagnetic force and flow field in the melt under the LVPMF were modeled and simulated to reveal the CET mechanism.It is considered that the CET should be attributed to the coupling effects of magnetic vibration and melt convection induced by the LVPMF.
基金supported by the National Basic Research Program of China ("973 Program") under grant Nos. (2010CB631200 and 2010CB631206)the National Natural Science Foundation of China undergrant No.50931004
文摘The process of grain selection in the spiral selector was investigated by both a ProCAST simulation based on a cellular automaton finite element（CAFE） model and experimental confirmation.The results show that the height of starter block,the spiral diameter and initial angle play an important role in grain selection.The dimension of selector should be maintained in a stable range to optimize the grain orientation and select a single crystal efficiently.A selector which can efficiently select a single crystal had been successfully designed.Grain orientation fluctuation in the spiral part was also studied by means of the variation of thermal condition.
